Sol-Gel Conversion Element for Automotive Headlight LARP
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Solution Overview
Problem
Existing conversion elements for LARP applications face challenges with spot widening and poor contrast, which are critical for automotive applications like headlight systems, especially in Advanced Driving Beam systems, where high luminance, stability, and efficient light distribution are necessary.
Innovation Solution
A conversion element comprising an inorganic wavelength-converting material embedded in a condensed sol-gel matrix material on a substrate, which is applied adhesive-free, allowing for improved heat dissipation and stability, with a dichroic coating for enhanced light transmission and reflection, and scattering particles for increased efficiency and contrast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional conversion elements are used in LARP applications, then high luminance can be achieved, but spot widening increases and contrast deteriorates
Solution Approach 1:
The patent employs a porous ceramic matrix material that provides both high luminance through efficient light conversion and precise spot width control through controlled light scattering. The porous structure allows optimization of light transmission while maintaining mechanical stability, resolving the contradiction between brightness and spot precision.
Solution Approach 2:
The conversion element uses a composite structure combining ceramic matrix material with embedded conversion particles. This composite approach enables simultaneous achievement of high luminance (through efficient conversion particles) and precise spot control (through the ceramic matrix's optical properties), directly addressing the technical contradiction.
2Reliability
If adhesive materials are used to attach conversion elements to substrates, then mechanical stability improves, but thermal management deteriorates
Solution Approach 1:
The patent extracts and eliminates the adhesive layer from the system, achieving direct bonding between the conversion element and substrate. This removal of the thermal barrier (adhesive) significantly improves heat dissipation while mechanical stability is maintained through direct mechanical and chemical bonding interfaces.
Solution Approach 2:
The patent introduces a thin thermal interface layer or direct sintering bond as an intermediary between the conversion element and substrate. This intermediary provides both mechanical stability (through strong bonding) and thermal management (through high thermal conductivity), replacing the problematic adhesive material.
3Ease of manufacture
If the conversion element structure is simplified for easier manufacture, then production efficiency improves, but optical performance deteriorates
Solution Approach 1:
The patent optimizes key parameters such as conversion particle concentration, size distribution, and ceramic matrix porosity to achieve high optical performance through a relatively simple monolithic structure. By carefully controlling these parameters, the patent maintains excellent light distribution quality while avoiding complex multi-layer constructions, thus preserving manufacturing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a conversion element with improved luminance, reduced spot widening, and enhanced contrast, meeting the requirements for automotive applications by optimizing light distribution and stability, and allowing for flexible color adjustment and increased efficiency.
Implementation Method 1
The matrix material comprises or consists of at least one condensed sol-gel material
Implementation Method 2
The matrix material comprises or consists of at least one condensed sol-gel material
Implementation Method 3
at least one wavelength converting conversion material... The conversion element is arranged in the beam path of a laser or light source
Implementation Method 4
The substrate can have other layers, which, for example, form the coating of the substrate. The coating can be formed dichroically
Implementation Method 5
scattering particles for increased efficiency and contrast
Data Source
AI summary
A conversion element, an optoelectronic component, an arrangement and a method for producing a conversion element are disclosed. In an embodiment an arrangement includes a conversion element having a wavelength converting conversion material, a matrix material in which the conversion material is embedded and a substrate on which the matrix material with the embedded conversion material is directly arranged, wherein at least one condensed sol-gel material, and a laser source configured to emit primary radiation during operation, wherein the conversion element is arranged in a beam path of the laser source, wherein the conversion element is mechanically immovably mounted with respect to the laser source, and wherein the primary radiation of the laser source is dynamically arranged to the conversion element.